Laminate Fabrics

ABSTRACT

The present invention provides laminate fabrics comprising two or more spunlaced fabric layers.

RELATED APPLICATIONS

The present invention claims the benefit of priority under 35 U.S.C.§119(e) to U.S. Patent Application No. 61/767,984, filed Feb. 22, 2013,the disclosure of which is incorporated herein by reference in itsentirety.

FIELD OF THE INVENTION

The present invention relates to laminate fabrics comprising two or morespunlaced fabric layers.

BACKGROUND

Spunlaced fabrics are produced by hydroentangling the fibers of afibrous substrate such as a batt or web of fibers. See, e.g., U.S. Pat.No. 3,403,862.

SUMMARY OF THE CLAIMED INVENTION

A first aspect of the invention is a laminate fabric comprising a firstnonwoven, spunlaced fabric layer and a second nonwoven, spunlaced fabriclayer, wherein each nonwoven, spunlaced fabric layer comprises athree-dimensional pattern on its face. The first and second nonwoven,spunlaced fabric layers are laminated together such that the back of thefirst nonwoven, spunlaced fabric layer is coupled to the back of thesecond nonwoven, spunlaced fabric layer. Thus, the faces of the firstand second nonwoven, spunlaced fabric layers face outward from the siteof coupling. This combination of fabric characteristics and lamination,creates a laminate fabric that is textile-like in handle, flexibility,strength, and durability. In some embodiments, the first and secondnonwoven, spunlaced fabric layers are coupled using an adhesive. In someembodiments, the laminate comprises a binder finish.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram depicting a cross-section of a laminate fabricaccording to some embodiments of the present invention.

FIG. 2 depicts four nonwoven, spunlaced fabric layers that may beincorporated into laminate fabrics of the present invention.

FIGS. 3A and 3B depict the face (A) and the back (B) of a nonwoven,spunlaced fabric layer that may be incorporated into laminate fabrics ofthe present invention.

FIG. 4 depicts a nonwoven, spunlaced fabric layer that may beincorporated into laminate fabrics of the present invention.

FIG. 5 depicts a nonwoven, spunlaced fabric layer that may beincorporated into laminate fabrics of the present invention.

FIG. 6 depicts a nonwoven, spunlaced fabric layer that may beincorporated into laminate fabrics of the present invention.

FIG. 7 depicts a nonwoven, spunlaced fabric layer that may beincorporated into laminate fabrics of the present invention.

DETAILED DESCRIPTION

The present invention is explained in greater detail below. Thisdescription is not intended to be a detailed catalog of all thedifferent ways in which the invention may be implemented or of all thefeatures that may be added to the instant invention. For example,features illustrated with respect to one embodiment may be incorporatedinto other embodiments, and features illustrated with respect to aparticular embodiment may be deleted from that embodiment. In addition,numerous variations and additions to the various embodiments suggestedherein, which do not depart from the instant invention, will be apparentto those skilled in the art in light of the instant disclosure. Hence,the following specification is intended to illustrate some particularembodiments of the invention, and not to exhaustively specify allpermutations, combinations and variations thereof.

It will be understood that when an element or layer is referred to asbeing “on”, “attached to”, “connected to”, “coupled to”, “coupled with”or “contacting” another element or layer, it can be directly on,connected or coupled to the other element or layer or interveningelements or layers may be present. In contrast, when an element isreferred to as being “directly on,” “directly connected to” or “directlycoupled to” another element or layer, there are no intervening elementsor layers present. It will be appreciated by those of skill in the artthat a structure referred to as being “directly on,” “directly connectedto, or “directly coupled to another structure may partially orcompletely cover one or more surfaces of the other structure. It willalso be appreciated by those of skill in the art that references to astructure or feature that is disposed “adjacent” another structure orfeature may have portions that overlap or underlie the adjacentstructure or feature.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the specification andrelevant art and should not be interpreted in an idealized or overlyformal sense unless expressly so defined herein. Well-known functions orconstructions may not be described in detail for brevity and/or clarity.

As used herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise.

As used herein, the term “about,” when used in reference to a measurablevalue such as an amount of mass, dose, time, temperature, and the like,is meant to encompass variations of 20%, 10%, 5%, 1%, 0.5%, or even 0.1%of the specified amount.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items.

As used herein, the terms “comprise,” “comprises,” “comprising,”“include”, “includes” and “including” specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof.

As used herein, the term “consists essentially of” (and grammaticalvariants thereof), as applied to the compositions and methods of thepresent invention, means that the compositions/methods may containadditional components so long as the additional components do notmaterially alter the composition/method. The term “materially alter,” asapplied to a composition/method, refers to an increase or decrease inthe effectiveness of the composition/method of at least about 20% ormore. For example, a component added to a composition of the presentinvention would “materially alter” the composition if it increases ordecreases the composition's durability by at least 20%.

As used herein, the terms “increase” and “enhance” (and grammaticalvariants thereof) refer to an increase in the specified parameter of atleast about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%,50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%,175%, 200%, 250%, 300% or more.

As used herein, the terms “inhibit” and “reduce” (and grammaticalvariants thereof) refer to a decrease in the specified parameter of atleast about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%,50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 99% or more.

As used herein, the term “three-dimensional pattern” refers to adiscernible regularity in the three-dimensional structure of a fabriclayer. In some embodiments, the three-dimensional structure of thefabric layer is discernibly regular over at least about 50%, 55%, 60%,65%, 70%, 75% 80%, 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%or 100% of the face of the fabric layer. A three-dimensional pattern maybe formed in a nonwoven, spunlaced fabric by/during the hydroentanglingprocess(es) used to produce the nonwoven, spunlaced fabric. That is, theparameters of the spunlacing process(es) used to produce a nonwoven,spunlaced fabric may be selectively adjusted such that the fibers in thefibrous substrate are reorganized to form a desired three-dimensionalpattern. In some embodiments, the parameters of the spunlacingprocess(es) are adjusted to produce a nonwoven, spunlaced fabric whosethree-dimensional pattern imparts textile-like absorbency, handle,flexibility, strength, and/or durability.

All publications, patent applications, patents, and other referencesmentioned herein are incorporated by reference in their entirety.

The present invention provides laminate fabrics comprising, consistingessentially of or consisting of two or more nonwoven, spunlaced fabriclayers.

As shown in FIG. 1, in some embodiments, the laminate fabric comprises afirst nonwoven, spunlaced fabric layer 1 and a second nonwoven,spunlaced fabric layer 2, wherein each nonwoven, spunlaced fabric layercomprises a three-dimensional pattern 1 p, 2 p on its face 1 f, 2 f. Thefirst and second nonwoven, spunlaced fabric layers are laminatedtogether such that the back of the first nonwoven, spunlaced fabriclayer 1 b is coupled to the back of the second nonwoven, spunlacedfabric layer 2 b (i.e., with the faces of the first and second nonwoven,spunlaced fabric layers 1 f, 2 f facing outward from the site ofcoupling 12). In some embodiments, the first and second nonwoven,spunlaced fabric layers 1, 2 are coupled using an adhesive 3. In someembodiments, the laminate fabric 0 comprises a finish that comprises oneor more binders (not shown).

Nonwoven, spunlaced fabric layers may comprise any suitablethree-dimensional pattern(s). In some embodiments, one or more of thenonwoven, spunlaced fabric layers comprises a three-dimensional patternthat mimics the three-dimensional texture of a woven textile (e.g.,hopsack, terrycloth or twill). In some embodiments, one or more of thenonwoven, spunlaced fabric layers comprises a three-dimensional patternsuch that one or more surfaces of the nonwoven, spunlaced fabric layer(e.g., the face of the nonwoven, spunlaced fabric layer) has an averagesurface roughness of at least about 5, 10, 15, 20, 25, 30, 35, 40, 45,50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 125, 150, 175, 200, 250,300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950,1000 or more microns (as measured in accordance with the KawabataEvaluation System (KES) using a KES-FB4 Surface Roughness Tester and/oras measured using a profilometer, for example). In some embodiments, oneor more of the nonwoven, spunlaced fabric layers comprises athree-dimensional pattern such that one or more surfaces of thenonwoven, spunlaced fabric layer (e.g., the face of the nonwoven,spunlaced fabric layer) has an average surface roughness of about 5 toabout 50 microns, about 25 to about 100 microns, about 100 to about 250microns, about 250 to about 500 microns or about 500 to about 1000microns (as measured in accordance with the KES using a KES-FB4 SurfaceRoughness Tester and/or as measured using a profilometer, for example).Surface roughness may be measured as the relief (in microns, forexample) from the lowest point of the surface to the highest point ofthe surface. The differential of the coefficient of friction (COF) mayalso be measured. For an aggressive surface the change in COF is roughergenerally for increased ΔCOF. In those embodiments wherein two or moreof the nonwoven, spunlaced fabric layers comprise a three-dimensionalpattern, their three-dimensional patterns may be the same orsubstantially the same. For example, the laminate fabric may comprise afirst nonwoven, spunlaced fabric layer and a second nonwoven, spunlacedfabric layer, wherein the first and second nonwoven, spunlaced fabriclayers comprise the same (or substantially the same) three-dimensionalpattern.

Nonwoven, spunlaced fabric layers may comprise any suitable type(s) offibers, including, but not limited to, natural fibers and syntheticfibers. In some embodiments, one or more of the nonwoven, spunlacedfabric layers comprises, consists essentially of or consists of naturalfibers. For example, one or more of the nonwoven, spunlaced fabriclayers may comprise, consist essentially of or consist of one or more ofthe following fiber types: bamboo, camel hair, graphite, cotton, flax,hemp, jute, polylactic acid, silk, sisal, wood pulp and wool (e.g.,alpaca, angora, cashmere, chiengora, guanaco, llama, mohair, pashmina,sheep and/or vicuña). In some such embodiments, one or more of thenonwoven, spunlaced fabric layers comprises, consists essentially of orconsists of one or more natural fibers selected from the groupconsisting of cotton, wood pulp and wool. In some embodiments, one ormore of the nonwoven, spunlaced fabric layers comprises, consistsessentially of or consists of synthetic fibers. For example, one or moreof the nonwoven, spunlaced fabric layers may comprise, consistessentially of or consist of one or more of the following fiber types:acrylic, carbon, fluorocarbon, glass, lyocell, rayon, melamine,modacrylic, polyacrylonitrile (e.g., oxidized polyacrylonitrile),polyamide (e.g., nylon and/or aramid) polybenzimidazole, polyester,polyimides, polylactic acid, polyolefin (e.g., polyethylene and/orpolypropylene), polyphenylene benzobisoxazole, polyphenylene sulfides,polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyvinylfluoride, polyvinylidene chloride, viscose (e.g., silica-modifiedviscose) and zylon. In some such embodiments, one or more of thenonwoven, spunlaced fabric layers comprises, consists essentially of orconsists of one or more synthetic fibers selected from the groupconsisting of acrylic, aramid (e.g., meta-aramid and/or para-aramid),modacrylic, nylon, polyester, polyethylene or polypropylene. In someembodiments, one or more of the nonwoven, spunlaced fabric layerscomprises, consists essentially of or consists of cellulosic fibers. Forexample, one or more of the nonwoven, spunlaced fabric layers maycomprise, consist essentially of or consist of one or more of thefollowing fiber types: bamboo, cellulose acetate, cellulose triacetate,cotton, flax, hemp, jute, lyocell, ramie, sisal, viscose (e.g.,silica-modified viscose), and wood pulp. In some such embodiments, oneor more of the nonwoven, spunlaced fabric layers comprises, consistsessentially of or consists of one or more cellulosic fibers selectedfrom the group consisting of cotton, lyocell, viscose (e.g.,silica-modified viscose), and wood pulp. In some embodiments, one ormore of the nonwoven, spunlaced fabric layers comprises, consistsessentially of or consists of bicomponent fibers. For example, one ormore of the nonwoven, spunlaced fabric layers may comprise, consistessentially of or consist of one or more fibers comprising at least twodistinct constituent monomers (e.g., polyester and polypropylene). Insome embodiments, one or more of the nonwoven, spunlaced fabric layerscomprises, consists essentially of or consists of continuous fibers. Forexample, one or more of the nonwoven, spunlaced fabric layers maycomprise, consist essentially of or consist of one or more spunbondedfibers (e.g., flash spunbonded fibers), one or more meltblown fibersand/or one or more spunbonded-meltblown-spunbonded composite fibers.

Nonwoven, spunlaced fabric layers may be laminated together using anysuitable means known in the art, including, but not limited to, adhesivebonding, needling, powder bonding, RF welding, thermal bonding andultrasonic bonding. In some embodiments, two nonwoven, spunlaced fabriclayers are laminated together by bonding the two layers at multiple,spaced apart locations, which may enhance the flexibility, softnessand/or handle of the laminate fabric. For example, the two nonwoven,spunlaced fabric layers may be laminated together using a web or net ofadhesive material (e.g., polyester, copolyester, polyamide, pressuresensitive SIS or SBS, APAO, polyolefin, EVA, urethane, moisture cureurethane, polypropylene, acrylic, and/or natural rubber) between the twolayers. In some embodiments, the nonwoven, spunlaced fabric layers inthe laminate fabric are not ultrasonicly bonded.

Nonwoven, spunlaced fabric layers may be laminated together in anysuitable orientation. In some embodiments, the nonwoven, spunlacedfabric layers are laminated together such that the laminate fabriccomprises a first three-dimensional pattern on its face and a secondthree-dimensional fabric on its back. For example, the laminate fabricmay comprise two nonwoven, spunlaced fabric layers, each with athree-dimensional pattern on the face thereof, and the backs of thenonwoven, spunlaced fabric layers may be laminated together such thatthe face of one nonwoven, spunlaced fabric layer becomes the face of thelaminate and the face of the other nonwoven, spunlaced fabric layerbecomes the back of the laminate. In some embodiments, the nonwoven,spunlaced fabric layers are laminated together such that thethree-dimensional patterns they comprise are aligned in the resultantlaminate fabric. For example, the laminate fabric may comprise twononwoven, spunlaced fabric layers, each with the same three-dimensionalpattern on its face, and the nonwoven, spunlaced fabric layers may belaminated together such that three-dimensional pattern on the face ofone nonwoven, spunlaced fabric layer is perfectly aligned with thethree-dimensional pattern of the face of the other nonwoven, spunlacedfabric layer.

Nonwoven, spunlaced fabric layers and laminate fabrics may be treatedwith any suitable finish, including, but not limited to finishes thatrender the nonwoven, spunlaced fabric layer or laminate fabric moreabrasion resistant, alcohol repellant, durable (e.g., wash durableand/or dry clean durable), elastic, electrically conductive, flameretardant, flexible, oil repellant, soil and/or stain repellant, UVresistant, anti-microbial, anti-fungal, low-linting, antistatic,wettable, absorbant and/or water repellant than it was prior toapplication of the finish. For example, the finish may comprise one ormore substances that impart antimicrobial and/or antifungal propertiesto the nonwoven, spunlaced fabric layer or laminate fabric. Similarly,the finish may comprise one or more substances that impart color to thenonwoven, spunlaced fabric layer or laminate fabric. In someembodiments, the finish is predominantly or exclusively present on oneor more surfaces of the nonwoven, spunlaced fabric layers or laminatefabric. For example, in a laminate fabric comprising two nonwoven,spunlaced laminate fabric layers, the finish may be predominantly orexclusively present on the face of one or both of the nonwoven,spunlaced fabric layers. In some embodiments, at least a portion of thefinish is present in the interior of the nonwoven, spunlaced fabriclayers or laminate fabric. For example, in a laminate fabric comprisingtwo nonwoven, spunlaced laminate fabric layers, the finish may bepresent in the interior of one or both of the nonwoven, spunlacedlaminate fabrics and/or in the boundary between the two nonwoven,spunlaced fabric layers. In some embodiments, the finish comprises,consists essentially of or consists of one or more substances thatincrease the durability of the nonwoven, spunlaced fabric layers orlaminate fabric. For example, the finish may comprise one or moreisocyanates (e.g., blocked ioscyanates). In some embodiments, the finishcomprises, consists essentially of or consists of one or more flameretardant chemistries. For example, the finish may comprise one or moreflame retardant antimony compounds (e.g., antimony oxides), one or moreflame retardant boron compounds (e.g., ammonium borate, borax, boricacid, ethylammonium borate and/or zinc borate), one or more flameretardant halogen compounds (e.g., ammonium bromide, ammonium chloride,brominated/chlorinated binders and/or brominated/chlorinated paraffin),one or more flame retardant nitrogen compounds (e.g., ammoniumpolyphosphate), one or more flame retardant phosphorous compounds (e.g.,ammonium borate, ammonium bromide, ammonium chloride, ammoniumpolyphosphate, ammonium sulfamate and/or ethanolylammonium borate)and/or one or more flame retardant sulfur compounds (e.g., ammoniumsulfamate). In some such embodiments, the finish comprises, consistsessentially of or consists of one or more flame retardant chemistriesselected from the group consisting of phosphorous compounds and nitrogencompounds. In some such embodiments, the finish comprises, consistsessentially of or consists of one or more flame retardant chemistriesselected from the group consisting of ammonium polyphosphate andammonium phosphate. In some embodiments, the finish comprises, consistsessentially of or consists of one or more antistats. For example, thefinish may comprise one or more salts, sodium chloride, sodium nitrate,sodium sulfate, phosphate esters and/or one or more quaternary ammoniumcompounds.

Nonwoven, spunlaced fabric layers and laminate fabrics may be finishedusing any suitable means known in the art, including, but not limitedto, coating, corona discharge, dipping, hot melt application, padfinishing, plasma finishing, printing, rotogravure, slot-dieapplication, spraying and vacuum metallization. In some embodiments, oneor more of the nonwoven, spunlaced fabric layers is treated with afinish prior to its incorporation into the laminate fabric. In someembodiments, one or more of the nonwoven, spunlaced fabric layers istreated with a finish after it is incorporated into the laminate fabric.In some embodiments, the laminate fabric is treated with a finishfollowing incorporation of all its nonwoven, spunlaced fabric layers. Insome embodiments, each of the nonwoven, spunlaced fabric layers in thelaminate fabric is treated with a finish that comprises one or morebinders. In some embodiments, fewer than all of the nonwoven, spunlacedfabric layers in the laminate fabric is treated with a finish thatcomprises one or more binders.

Nonwoven, spunlaced fabric layers and laminate fabrics may undergo anysuitable mechanical treatment known in the art, including, but notlimited to, calendaring, creping, embossing, ring rolling andstretching. In some embodiments, one or more of the nonwoven, spunlacedfabric layers is mechanically treated prior to its incorporation intothe laminate fabric. In some embodiments, the laminate fabric ismechanically treated following incorporation of all its nonwoven,spunlaced fabric layers.

Laminate fabrics of the present invention may demonstrate enhancedstrength. In some embodiments, the strength of the laminate fabric isincreased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%,35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%,125%, 150%, 175%, 200%, 250%, 300% or more as compared to a controlfabric (i.e., a fabric that lacks the three-dimensional patterning ofthe laminate fabric but is otherwise identical to the laminate fabric).In some embodiments, the strength of the laminate fabric is increased byat least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%,45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%,175%, 200%, 250%, 300% or more as compared to a single layer fabrichaving the same amounts/types of fibers, weight, thickness and finish asthe laminate fabric. In some embodiments, strength is measured inaccordance with INDA Standard Test Method WSP 110.1 (04) and/or INDAStandard Test Method WSP 110.5 (05).

Laminate fabrics of the present invention may demonstrate enhancedabsorption capabilities. In some embodiments, the absorbency of thelaminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%,15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%,85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more ascompared to a control fabric (i.e., a fabric that lacks thethree-dimensional patterning of the laminate fabric but is otherwiseidentical to the laminate fabric). In some embodiments, the absorbencyof the laminate fabric is increased by at least about 1%, 2%, 3%, 4%,5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%,75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% ormore as compared to a single layer fabric having the same amounts/typesof fibers, weight, thickness and finish as the laminate fabric. In someembodiments, absorption is measured in accordance with INDA StandardTest Method WSP 10.1 (04).

Laminate fabrics of the present invention may demonstrate enhanceddurability (e.g., wash durability, as measured by weight loss and/orshrinkage amounts after laundering). In some embodiments, the durabilityof the laminate fabric is increased by at least about 1%, 2%, 3%, 4%,5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%,75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% ormore as compared to a control fabric (i.e., a fabric that lacks thethree-dimensional patterning of the laminate fabric but is otherwiseidentical to the laminate fabric). In some embodiments, the durabilityof the laminate fabric is increased by at least about 1%, 2%, 3%, 4%,5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%,75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% ormore as compared to a single layer fabric having the same amounts/typesof fibers, weight, thickness and finish as the laminate fabric. In someembodiments, durability is measured in accordance with INDA StandardTest Method WSP 150.2 (05).

Laminate fabrics of the present invention may demonstrate enhancedabrasion resistance. In some embodiments, the abrasion resistance of thelaminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%,15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%,85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more ascompared to a control fabric (i.e., a fabric that lacks thethree-dimensional patterning of the laminate fabric but is otherwiseidentical to the laminate fabric). In some embodiments, the abrasionresistance of the laminate fabric is increased by at least about 1%, 2%,3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%,70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300%or more as compared to a single layer fabric having the sameamounts/types of fibers, weight, thickness and finish as the laminatefabric. In some embodiments, absorption is measured in accordance withINDA Standard Test Method WSP 20.2 (05) and/or INDA Standard Test MethodWSP 20.4 (03).

Laminate fabrics of the present invention may demonstrate enhanced skidresistance. In some embodiments, the skid resistance of the laminatefabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%,25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%,95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to acontrol fabric (i.e., a fabric that lacks the three-dimensionalpatterning of the laminate fabric but is otherwise identical to thelaminate fabric). In some embodiments, the skid resistance of thelaminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%,15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%,85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more ascompared to a single layer fabric having the same amounts/types offibers, weight, thickness and finish as the laminate fabric. In someembodiments, skid resistance is measured in accordance with INDAStandard Test Method WSP 90.3 (05).

Accordingly, laminate fabrics of the present invention may be suitablefor use in numerous applications, including, but not limited to, towels(e.g., dish towels, bar towels, wash towels, industrial shop tools, foodservice towels, scrubbing towels, bath towels, clean room towels and/orsurgical towels), wipes (e.g., scrubbing wipes and/or cosmetic wipes),medical drapes, window treatments, mattresses, abrasive cloths, tackcloths, dust cloths, mops and car wash mitts.

As shown in Table 1 below, laminate fabrics of the present invention mayexhibit properties comparable to those of woven towels.

TABLE 1 Finished laminate Finished laminate comprising comprisingadhesively bonded adhesively bonded wood pulp-polyester Stan- woodpulp-polyester spunlaced fabric dard spunlaced fabric layers (finishedas woven layers (unfinished) in Example 5 below) towel Avg. Avg. Avg.Basis 3.10 2.78 6.03 Weight, osy Caliper, in 0.034 0.022 0.034 MD Grabs50.0 45.1 28 XD Grabs 26.7 25.1 47.4 Wet 3.5 4.5 4 Crocking Dry 4.5 5 5Crocking MD Bonds, 435.1 187 N/A g/in XD Bonds, 361.0 229.5 N/A g/inHOM, MD 32.2 25.4 9.725 HOM, XD 7.3 8.7 9.725 Water 1 1 1 Drop, s AbsRate, 4.0 2.8 3.3 s Abs Cap, % 826.5 768.8 499 Dry 3839 759 326975Particle Count, #/ft³/min

EXAMPLES

The following examples are not intended to be a detailed catalog of allthe different ways in which the present invention may be implemented orof all the features that may be added to the present invention. Personsskilled in the art will appreciate that numerous variations andadditions to the various embodiments may be made without departing fromthe present invention. Hence, the following descriptions are intended toillustrate some particular embodiments of the invention, and not toexhaustively specify all permutations, combinations and variationsthereof.

Example 1

Laminate fabrics comprising two nonwoven, spunlaced fabric layers wereformed. Each of the nonwoven, spunlaced fabric layers had a basis weightof approximately 2.2 osy and comprised approximately 55% wood pulp andapproximately 45% polyester. Each of the nonwoven, spunlaced fabriclayers had a face comprised predominantly of wood pulp fibers and anopposing face comprised predominantly of polyester fibers. Each of thenonwoven, spunlaced fabric layers was treated with a finish comprising0.1% FoamPress NS-99, 0.3% Tergitol™ GR-5M (Dow®), 1.5% Trixene AquaB.I. 201 (Baxenden Chemicals Ltd., United Kingdom) and 3.0% Binder VC-1(Momentive Specialty Chemicals, Roebuck S.C.) (by weight, based upon theweight of the finish bath (% owb)). The finish was applied to each ofthe nonwoven, spunlaced fabric layers using a dip-and-nip applicationmethod with an approximate wet pick-up of 130%. Following application ofthe finish, each of the nonwoven, spunlaced fabric layers was dried andcured in a conventional tenter frame overn for approximately 20 secondsat 190° C. Griltex 1332 (EMS-CHEMIE AG (North America), Inc., Sumter,S.C.) was applied in discrete dots (187 dots per square inch) to thepredominantly polyester face of one of the nonwoven, spunlaced fabriclayers using a gravure application method with an approximate add-onweight of 20 grams per square meter. The predominantly polyester face ofthe other nonwoven, spunlaced fabric layer was placed against theadhesive-laden, predominantly polyester face of the first nonwoven,spunlaced fabric layer, and the two nonwoven, spunlaced fabric layersare nipped together by two rolls.

The laminate fabrics had a basis weight in the range of approximately4.4 to 4.6 osy, a grab tensile of approximately 70 to 80 pounds in themachine direction and approximately 35 to 50 pounds in the crossdirection, a bond strength of approximately 800 to 1000 grams/inch inboth the machine and cross directions, a handle of approximately 80 to115 grams in the machine direction and approximately 30 to 55 in thecross direction, and an absorption capacity of approximately 500 to 650percent. The laminate fabric was durable to 180° F. industrial washing,with bleach, and 180° F. drying for at least 5 cycles.

The laminate fabrics were then compacted at 3-4% compaction to increasetheir drape. The laminate fabrics were compacted using a smooth rolleron a micrex unit.

Each laminate fabric was approximately 17 inches long and approximately19 inches wide.

Example 2

Several (17″×20″) swatches of greige 1.65 osy DuPont style 9995woodpulp/polyester spunlaced fabric (light blue color) were finished inthe lab. The fiber content of the fabric was 55% woodpulp fiber/45%polyester fiber. The swatches were finished using a dip and nip(saturation) type finish with the following finish components. The wetpick-up of the finish measured 106%. The lab oven temperature was set at177° C. (350° F.) and the speed (dwell time) at 30 seconds.

Lab #320-146 Mix #1

Finish component Purpose % o.w.b. FoamPress NS-99 Defoamer 0.1 TergitolTMN-6 Surfactant 0.2 Propylene Glycol Processing aid 0.6 BY 16-876Silicone rewetter 0.9 Ultraphil TG Surfactant 0.9 Water 97.3Lab-finished swatches were stretched approximately 8.0% in the labbefore being ultrasonically bonded using pattern #320-130A (small dotpattern). The ultrasonic bonding unit was set for a pressure of 35 psi,and amplitude of 85%. Two swatches were ultrasonically bonded togetherwith the woodpulp sides facing out. The resulting laminate fabric hadthe physical properties described in Table 2 below.

TABLE 2 Basis weight (oz/yd2) 2.8 (ASTM D3776) Grab Tensile (lbs.) MD 35(ASTM D5034) XD 21 Elongation (%) MD 52 (ASTM D5034) XD 105 Bondstrength (grams/inch) MD 56 AATCC 136 XD 51 Caliper (inches) 0.025 (ASTMD1777) Handle-o-meter MD 30 (grams/force) (4″ × 7″, 20 mm gap) XD 13(INDA 90.3) Dry crock (rating) 4.5 (AATCC 8) Wet crock (rating) 4.5(AATCC 8) Absorbency Rate (seconds) 1.5 (INDA 10.1) Absorbent Capacity(%) 769 (INDA 10.1) Total liquid capacity/sq.yd. 24.6 Ounces/sq. yard

Example 3

Laminate fabrics comprising two nonwoven, spunlaced fabric layers (Style22016 from Spuntech Industries, Roxboro, Inc.) were formed. Each of thenonwoven, spunlaced fabric layers had a basis weight of approximately2.5 to 3.0 osy and comprised of approximately 50% viscose andapproximately 50% polyester. The out surface of each nonwoven, spunlacedfabric layer comprised about 60 to 95% viscose. Each of the nonwoven,spunlaced fabric layers was spunlaced from a layered web with a patternthat allowed for apertures and a texture surface. A rubber-basedadhesive (577, 3M, Minneapolis, Minn.) was sprayed on the face of one ofthe nonwoven, spunlaced fabric layers with an approximate add-on weightof 10 grams per square meter. The other nonwoven, spunlaced fabric layerwas placed against the adhesive-laden, polyester face of the firstnonwoven, spunlaced fabric layer to form a laminate fabric havingviscose-rich outer surfaces and the properties described in Table 3below.

TABLE 3 Basis weight (oz/yd2) 5.65 (ASTM D3776) Grab Tensile (lbs.) MD86 (ASTM D5034) XD 50 Elongation (%) MD 44 (ASTM D5034) XD 108 Bondstrength (grams/inch) MD na AATCC 136 XD na Caliper (inches) 0.050 (ASTMD1777) Handle-o-meter MD 70 (grams/force) (4″ × 7″, 20 mm gap) XD 21(INDA 90.3) Dry crock (rating) 5 (AATCC 8) Wet crock (rating) 5 (AATCC8) Absorbency Rate (seconds) 2.6 (INDA 10.1) Absorbent Capacity (%) 784(INDA 10.1) Total liquid capacity/sq. yd. 43.9 Ounces/sq. yard

Example 4

A woodpulp/lyocell spunlaced fabric, style 8705, was obtained from theDuPont Company. This fabric was composed of 100% cellulose, with 55% ofthe web being woodpulp, and 45% of the web lyocell fiber. The fabricsexhibited strong orientation of the wood fibers to one side of thefabric with the viscose fibers residing on the other side. The fabricswere laminated using 3M 577 adhesive with the lyocell-rich surfacesfacing towards the center (FIG. 4). The resulting laminate fabric hadthe physical properties described in Table 4 below.

TABLE 4 Basis weight (oz/yd2) 4.65 (ASTM D3776) Grab Tensile (lbs.) MD40.3 (ASTM D5034) XD 28.9 Elongation (%) MD 23 (ASTM D5034) XD 62 Bondstrength (grams/inch) MD Na AATCC 136 XD Na Caliper (inches) .024 (ASTMD1777) Handle-o-meter MD 184 (grams/force) (4″ × 7″, 20 mm gap) XD 34(INDA 90.3) Dry crock (rating) 5 (AATCC 8) Wet crock (rating) 4 (AATCC8) Absorbency Rate (seconds) 1.3 (INDA 10.1) Absorbent Capacity (%) 569(INDA 10.1) Total liquid capacity/sq. yd. 26.5 Ounces/sq. yard

Example 5

A woodpulp/polyester spunlaced fabric; style 8868, was obtained from theDuPont Company. This fabric was 55% woodpulp and 45% polyester, and wasentangled with a screen design that created a patterned and aperturestructure, Two rolls of this fabric were laminated with the polyesterrich side of the fabrics facing inwards, using a rotary ultrasonicbonder from Branson Inc. Bond pattern was a dot shape at about 11% bondarea. Speed was 50 ypm (yards per minute). The resulting laminate fabrichad the physical properties described in Table 5 below.

TABLE 5 Basis weight (oz/yd2) 3.49 (ASTM D3776) Grab Tensile (lbs.) MD46 (ASTM D5034) XD 30 Elongation (%) MD 22 (ASTM D5034) XD 87 Bondstrength (grams/inch) MD 56 AATCC 136 XD 93 Caliper (inches) .022 (ASTMD1777) Handle-o-meter(grams/force) MD 81 (4″ × 7″, 20 mm gap) XD 14(INDA 90.3) Dry crock (rating) 5 (AATCC 8) Wet crock (rating) 4 (AATCC8) Absorbency Rate (seconds) 2.4 (INDA 10.1) Absorbent Capacity (%) 667(INDA 10.1) Total liquid capacity/sq. yd. 16.0 Ounces/sq. yard

Example 6

A particular example consisted of a bi-laminate towel created from twolayers of DuPont® Sontara® wood pulp/polyester spunlace, style number90508. The greige material was light blue in color, with a basis weightof 1.65 osy, and was comprised of 55% polyester and 45% wood pulp, withone side having a greater concentration of wood pulp and the remainingside being rich in polyester. The greige material had also undergone asecondary process during manufacturing, which created a more texturedsurface.

Single layers of the greige material were pad finished in a bath via the“dip and nip” method with a binder finish comprised of the chemicals inconcentrations listed in Table 6, below. The wet pick up achieved wasroughly 100%. FoamPress NS-99 (The Marlin Company, Inc.) was present inthe mix in order to reduce the amount of foaming encountered in thefinishing pan. Tergitol TMN-6 (Univar) was used to enhance the absorbentproperties of the towel. Nacrylic X-4484 (Celanese Ltd.), an acrylicbinder, was used to soften the hand, and aid in the control of lint.Ammonium hydroxide was present in the finish in order to keep the binderfrom curing in the pan, and is known to flash off in the oven as thematerial is dried. The fabric was pad finished, and run through a tenterframe and oven where it was stretched approximately 10% from theoriginal greige width. The fabric temperature, upon exiting the oven,was 285° F.-300° F. in order to cure the acrylic binder properly.

TABLE 6 Component #/100 gal Water 816.15 FoamPress NS-99 1 TergitolTMN-6 1.25 Ammonium Hydroxide 0.6 Nacrylic X-4484 15

Two single layers of finished material were then laminated together viaultrasonic bonding in a face to face relationship, whereas the polyesterrich sides of the fabric are in contact with one another, leaving thetwo wood pulp rich sides exposed. A bond pattern with approximately4-12% bond area, comprised of rectangular bond points with roundededges, was used to ultrasonically laminate the materials. The bondingoccurred at 38 yards/min, and resulted in bonds that averaged 188 Win inthe MD direction and 213 g/in in the XD direction.

The ultrasonically laminated material was then subjected to microcrepingin order to soften the hand and create a more “drapeable” product. Inthis instance, a compression rate of 4-5% was employed at a speed of 133yards/min. Additionally, a smooth roll was used in the microcreper, asopposed to a comb and groove, or an additional type of configuration.However, both comb and groove and smooth rolls have been used on thismaterial in past trials.

The finished, ultrasonically bonded and microcreped laminate was thenfolded using a FMC Corporation Hudson Sharp towel folding machine, whereit underwent a modified W fold with Grab Tab®. This folding styleemploys a folding scheme of one half fold, followed by a full fold, thenpartial, partial, full, and one half fold in the MD direction. In the XDdirection, the towel underwent one full fold, resulting in a towel thathas a folded dimension of 5.5″ by 8.5″. The towel folding machine ranapproximately 60-80 yards/min. The resulting laminate fabric had thephysical properties described in Table 7 below.

TABLE 7 Basis Weight, osy 2.98 Water Drop, s 1 MD Grab Tensile, lbf 39.6XD Grab Tensile, lbf 22.1 Caliper, in 0.027 MD Handle-o-meter 11.8 XDHandle-o-meter 5.5 Wet Crocking 4.5 Dry Crocking 4.5 Absorbency Rate, s2.97 Absorbent Capacity, % 930.2 Dry Particle Count, 1,846 #/ft³/min

Example 7

A woodpulp/polyester spunlaced fabric from DuPont, style 9995, with abasis weight of 1.65 ounces per square yard, is composed ofapproximately 55% woodpulp and 45% polyester. The woodpulp ispredominately on one side of the fabric and the polyester predominatelyon the other side. Two rolls of this greige (unfinished) fabric arelaminated together with the polyester rich side of each fabric facinginward. The method of lamination is a rotary ultrasonic bonder using adot shaped pattern with approximately 11% bond area. The machine speedfor the ultrasonic bonding step is 55 feet per minute. The propertiesshown in Table 8 below were obtained when two layers of style 9995unfinished spunlaced fabric were ultrasonically bonded.

TABLE 8 Basis weight (oz/yd2) 3.20 (ASTM D3776) Grab Tensiles (lbs.) MD38 (ASTM D5034) XD 23 Caliper (inches) 0.038 (ASTM D1777) Bond Strength(grams/inch) MD 134 (AATCC 136) XD 150 Absorbency Rate (seconds) 1.5(INDA 10.1) Absorbent Capacity (%) 1,014 (INDA 10.1) Handle-o-meter(grams) MD 34 (INDA 90.3) XD 23

After bonding the fabric was run through a micrex machine which utilizesa smooth roll pattern and a 5.2% compression setting. The line speed forthe micrex machine was 400 feet per minute. The properties for themicrexed material are set forth in Table 9 below.

TABLE 9 Basis weight (oz/yd2) 3.31 (ASTM D3776) Handle-o-meter (grams)MD 12.3 INDA 90.3 XD 4.3 Caliper (inches) 0.030 ASTM D1777 Grab Tensiles(lbs.) MD 45 (ASTM D5034) XD 21

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. The invention is defined by the following claims, withequivalents of the claims to be included therein.

1. A laminate fabric, comprising: a first nonwoven, spunlaced fabriclayer comprising a front surface and a back surface opposite the frontsurface, said front surface comprising a first three-dimensionalpattern; and a second nonwoven, spunlaced fabric layer comprising afront surface and a back surface opposite the front surface, said frontsurface comprising a second three-dimensional pattern, wherein the firstand second nonwoven, spunlaced fabric layers are laminated together suchthat the back surface of the first nonwoven, spunlaced fabric layer iscoupled to the back surface of the second nonwoven, spunlaced fabriclayer.
 2. The laminate fabric of claim 1, wherein the firstthree-dimensional pattern and the second three-dimensional pattern aresubstantially the same.
 3. The laminate fabric of claim 1, wherein thefirst three-dimensional pattern and the second three-dimensional patternare aligned such that the laminate fabric appears to comprise oneconsistent pattern throughout the depth of the fabric.
 4. The laminatefabric of claim 1, wherein the first nonwoven, spunlaced fabric layercomprises one or more fibers selected from the group consisting ofcellulose, viscose and lyocell.
 5. The laminate fabric of claim 1,wherein the first nonwoven, spunlaced fabric layer comprises one or morefibers selected from the group consisting of polyester, polyethylene andpolypropylene.
 6. The laminate fabric of claim 1, wherein the secondnonwoven, spunlaced fabric layer comprises one or more fibers selectedfrom the group consisting of cellulose, viscose and lyocell.
 7. Thelaminate fabric of claim 1, wherein the second nonwoven, spunlacedfabric layer comprises one or more fibers selected from the groupconsisting of polyester, polyethylene and polypropylene.
 8. The laminatefabric of claim 1, wherein the first and second nonwoven, spunlacedfabric layers are laminated together using an adhesive.
 9. The laminatefabric of claim 1, wherein the first three-dimensional pattern isgenerated by the spunlacing process used to form the first nonwoven,spunlaced fabric.
 10. The laminate fabric of claim 1, wherein the secondthree-dimensional pattern is generated by the spunlacing process used toform the second nonwoven, spunlaced fabric.
 11. The laminate fabric ofclaim 1, wherein the laminated fabric is a towel.
 12. The laminatefabric of claim 1, wherein at least one of the first and secondnonwoven, spunlaced fabric layers has been treated with a finishcomprising an antimicrobial agent, an antistat, a flame retardant, asurfactant, a wetting agent, a binder, a cross-linker, and/or a blockedisocyanate.
 13. The laminate fabric of claim 1, wherein the averagesurface roughness of the front surface of the first nonwoven, spunlacedfabric layer is at least about 50 microns.
 14. The laminate fabric ofclaim 1, wherein the average surface roughness of the front surface ofthe first nonwoven, spunlaced fabric layer is about 100 to about 250microns.
 15. The laminate fabric of claim 1, wherein the average surfaceroughness of the front surface of the second nonwoven, spunlaced fabriclayer is at least about 50 microns.
 16. The laminate fabric of claim 1,wherein the average surface roughness of the front surface of the secondnonwoven, spunlaced fabric layer is about 100 to about 250 microns. 17.A laminate fabric, comprising: a first nonwoven, spunlaced fabric layercomprising a front surface and a back surface opposite the frontsurface, said front surface comprising a first three-dimensionalpattern; and a second nonwoven, spunlaced fabric layer comprising afront surface and a back surface opposite the front surface, said frontsurface comprising a second three-dimensional pattern, wherein the firstand second nonwoven, spunlaced fabric layers are laminated together suchthat the back surface of the first nonwoven, spunlaced fabric layer iscoupled to the back surface of the second nonwoven, spunlaced fabriclayer, wherein the first and second three-dimensional patterns resultedfrom the spunlacing process(es) used to form the first and secondnonwoven, spunlaced fabric layers.
 18. The laminate fabric of claim 17,wherein the first nonwoven, spunlaced fabric layer comprises cellulose,viscose and/or lyocell fibers, as well as polyester, polyethylene and/orpolypropylene fibers.
 19. The laminate fabric of claim 17, wherein thesecond nonwoven, spunlaced fabric layer comprises cellulose, viscoseand/or lyocell fibers, as well as polyester, polyethylene and/orpolypropylene fibers.
 20. The laminate fabric of claim 17, wherein thefirst and second nonwoven, spunlaced fabric layers are laminatedtogether using an adhesive.